Sensor interrogation

ABSTRACT

A method of testing a system, which has at least one electrochemical sensor for detecting an analyte gas within a housing of the system, and the housing has an inlet, includes exhaling in the vicinity of the inlet of the housing of the system and measuring a response to exhaled breath to test one or more transport paths of the system. Measuring the response to exhaled breath may, for example, include measuring the response of a sensor within the housing of the system that is responsive to the presence of exhaled breath. The sensor responsive to the presence of exhaled breath may, for example, include an electrochemically active electrode responsive to a gas within exhaled breath. The electrochemically active electrode may, for example, be responsive to carbon dioxide or to oxygen.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation patent application of U.S. patent application Ser. No. 13/650,613, filed on Oct. 12, 2012, which claims benefit of U.S. Provisional Patent Application Ser. No. 61/547,245, filed Oct. 14, 2011, and U.S. Provisional Patent Application Ser. No. 61/698,153, filed Sep. 7, 2012, the disclosures of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

The following information is provided to assist the reader in understanding certain technology including, for example, the devices, systems and/or methods disclosed below and representative environments in which such technology may be used. The terms used herein are not intended to be limited to any particular narrow interpretation unless clearly stated otherwise in this document. References set forth herein may facilitate understanding of the technology or the background thereof. The disclosure of all references cited herein are incorporated by reference.

Prudence dictates that gas detection instrumentation be tested regularly for functionality. It is a common practice to, for example, perform a “bump check,” or functionality check on portable gas detection instrumentation on a daily basis. The purpose of this test is to ensure the functionality of the entire gas detection system, commonly referred to as an instrument. A periodic bump check or functionality check may also be performed on a permanent gas detection instrument to, for example, extend the period between full calibrations. Gas detection systems include at least one gas sensor, electronic circuitry and a power supply to drive the sensor, interpret its response and display its response to the user. The systems further include a housing to enclose and protect such components. A bump check typically includes: a) applying a gas of interest (usually the target gas or analyte gas the instrument is intended to detect); b) collecting and interpreting the sensor response; and c) indicating to the end user the functional state of the system (that is, whether or not the instrument is properly functioning).

Such bump tests are performed regularly and, typically, daily. Bump checks provide a relatively high degree of assurance to the user that the gas detection device is working properly. The bump check exercises all the necessary functionalities of all parts of the gas detection device in the same manner necessary to detect an alarm level of a hazardous gas. In that regard, the bump check ensures that there is efficient gas delivery from the outside of the instrument, through any transport paths (including, for example, any protection and/or diffusion membranes) to contact the active sensor components. The bump check also ensures that the detection aspect of the sensor itself is working properly and that the sensor provides the proper response function or signal. The bump check further ensures that the sensor is properly connected to its associated power supply and electronic circuitry and that the sensor signal is interpreted properly. Moreover, the bump check ensures that the indicator(s) or user interface(s) (for example, a display and/or an annunciation functionality) of the gas detection instrument is/are functioning as intended.

However, a periodic/daily bump check requirement has a number of significant drawbacks. For example, such bump checks are time consuming, especially in facilities that include many gas detection systems or instruments. The bump check also requires the use of expensive and potentially hazardous calibration gases. Further, the bump check also requires a specialized gas delivery system, usually including a pressurized gas bottle, a pressure reducing regulator, and tubing and adapters to correctly supply the calibration gas to the instrument. The requirement of a specialized gas delivery system often means that the opportunity to bump check a personal gas detection device is limited in place and time by the availability of the gas delivery equipment.

SUMMARY OF THE INVENTION

In one aspect, a method of testing a system, which has at least one electrochemical sensor for detecting an analyte gas within a housing of the system, and the housing has an inlet, includes exhaling in the vicinity of the inlet of the housing of the system and measuring a response to exhaled breath to test one or more transport paths of the system. Measuring the response to exhaled breath may, for example, include measuring the response of a sensor within the housing of the system that is responsive to the presence of exhaled breath. The sensor responsive to the presence of exhaled breath may, for example, include an electrochemically active electrode responsive to a gas within exhaled breath. The electrochemically active electrode may, for example, be responsive to carbon dioxide or to oxygen.

The method may further include simulating the presence of the analyte gas electronically and measuring a response of the electrochemical sensor to the electronic simulation. In a number of embodiments, a constant current is caused to flow between a first working electrode and a counter electrode of the electrochemical sensor, and the measured response is a potential difference. In a number of embodiments, a constant potential difference is maintained between a first working electrode and a counter electrode of the electrochemical sensor, and the measured response is a current. The electrochemical sensor may, for example, be an amperometric sensor.

In a number of embodiments, the electrochemical sensor includes a first working electrode responsive to the analyte gas and a second working electrode responsive to a gas within exhaled breath. The electrochemical sensor may, for example, include a sensor housing including at least one inlet into an interior of the sensor housing wherein the first working electrode and the second working electrode are positioned within the sensor housing. Each of the first working electrode and the second working electrode may, for example, independently comprise an eletrocatalytically active material deposited upon a porous membrane through which gas can diffuse.

In another aspect, a system includes a system housing, at least one inlet formed in the system housing, at least one electrochemical sensor for detecting an analyte gas within the system housing, and at least one sensor responsive to the presence of exhaled breath within the system housing. The sensor responsive to the presence of exhaled breath may, for example, include an electrochemically active electrode responsive to a gas within exhaled breath. The electrochemically active electrode may, for example, be responsive to carbon dioxide or to oxygen.

The system may further include a system to electronically interrogate the electrochemical sensor. The system to electronically interrogate the electrochemical sensor may, for example, include circuitry to simulate the presence of the analyte gas electronically and to measure a response of the electrochemical sensor to the electronic simulation. In a number of embodiments, the circuitry is adapted to cause a constant current to flow between a first working electrode and a counter electrode of the electrochemical sensor, and the measured response is a potential difference. In a number of embodiments, the circuitry is adapted to maintain a constant potential difference between a first working electrode and a counter electrode of the electrochemical sensor and the measured response is a current.

The electrochemical sensor may, for example, include a first working electrode responsive to the analyte gas and a second working electrode responsive to a gas within exhaled breath. The electrochemical sensor may, for example, include a sensor housing including at least one inlet into an interior of the sensor housing, wherein the first working electrode and the second working electrode is positioned within the sensor housing. Each of the first working electrode and the second working electrode may, for example, independently include an eletrocatalytically active material deposited upon a porous membrane through which gas can diffuse.

In a further aspect, a system for detecting at least one analyte gas, includes a system housing comprising an inlet system and an electrochemical gas sensor within the housing and in fluid connection with the inlet system. The electrochemical sensor is responsive to the at least one analyte gas. The system further includes at least one sensor within the housing and in fluid connection with the inlet system which is responsive to at least one driving force created in the vicinity of the inlet system other than by application of the at least one analyte gas or a simulant gas to which the electrochemical sensor is responsive to provide an indication of a state of a transport path between the inlet system and the electrochemical gas sensor.

The driving force may, for example, be a change in the concentration of a gas cause by exhalation of breath, a change in humidity, a change in temperature, a change in pressure, or a change in flow. In a number of embodiments, the driving force is created by exhalation of breath in the vicinity of the inlet system.

In still a further aspect, a method of testing at least one transport path in a system having a housing and an inlet in the housing, wherein a primary function of the system is other than to measure a property of exhaled breath; includes exhaling in the vicinity of the inlet of the housing and measuring a response to exhaled breath to test the at least one transport path of the system.

The present invention, along with the attributes and attendant advantages thereof, will best be appreciated and understood in view of the following detailed description taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a user exhaling in a manner that the user's exhaled breath impinges upon an inlet of a system including a housing enclosing a sensor that is sensitive to at least one property of exhaled breath.

FIG. 2A illustrates a schematic, cross-sectional view of an embodiment of a system or instrument including at least one sensor which includes a first working electrode sensitive or responsive to an analyte and a second electrode sensitive or responsive to a driving force associated, for example, with the presence of exhaled breath.

FIG. 2B illustrates an enlarged side, cross-sectional view of a portion of the sensor of FIG. 2A including a housing lid in which a gas inlet hole is formed to be in fluid connection with a gas diffusion space and a porous gas diffusion membrane, wherein the first working electrode and the second working electrode are formed on or attached to an interior side of the diffusion membrane.

FIG. 2C illustrates a bottom view of the portion of the sensor illustrated in FIG. 2B.

FIG. 3A illustrates a perspective exploded view of another embodiment of a sensor including a first working electrode sensitive or responsive to an analyte and a second electrode sensitive or responsive to the presence of exhaled breath, wherein the first working electrode is formed on a first diffusion membrane and the second working electrode is formed on a second diffusion membrane.

FIG. 3B illustrates a cross-sectional view of the sensor of FIG. 3A within an instrument or system housing.

FIG. 3C illustrates an enlarged side, cross-sectional view of a portion of the sensor of FIG. 3A including a housing lid in which two gas inlet holes are formed, wherein each of the first working electrode and the second working electrode are in general alignment with one of the two gas inlet holes.

FIG. 3D illustrates a bottom view of the portion of the sensor illustrated in FIG. 3C.

FIG. 3E illustrates a schematic, cross-sectional view of another embodiment of a sensor including a first working electrode sensitive or responsive to an analyte and a second electrode sensitive or responsive to the presence of exhaled breath, wherein the first working electrode is formed on a first diffusion membrane positioned in a first cell and the second working electrode is formed on a second diffusion membrane positioned in a second cell.

FIG. 3F illustrates a side, cross-sectional view of a portion of another embodiment of a sensor including a housing having an inlet in the form of an extending slot and a diffusion member in fluid connection with the inlet.

FIG. 3G illustrates a top view of the sensor of FIG. 3F.

FIG. 4 illustrates a study of the response of the sensor of FIG. 3A, wherein the first working electrode is sensitive to hydrogen sulfide and the second working electrode is sensitive to oxygen, when challenged with exhaled breath, followed by a mixture of 15 vol-% oxygen and 20 ppm hydrogen sulfide, followed by nitrogen.

FIG. 5A illustrates a ribbon and a wire which may be used to form sensor elements in the systems hereof, which is adapted to measure a response to, for example, exhaled breath to test one or more transport paths of the system.

FIG. 5B illustrates sensor elements hereof including a conductive ribbon and a conductive wire upon which an electrocatalytic material is coated or immobilized.

FIG. 5C illustrates a sensor element hereof including an extending ribbon having a rectangular end member which is wider than the extending ribbon

FIG. 5D illustrates the sensor element of FIG. 5C having an electrocatalytic material immobilized on the end member thereof.

FIG. 5E illustrates a sensor element hereof including an extending wire having a spiraled section on an end thereof.

FIG. 5F the sensor element of FIG. 5E including an electrocatalytic material immobilized on the spiraled section thereof.

FIG. 6 illustrates an embodiment of an interdigitated electrode system hereof wherein a first branch of the electrode system includes a first electrocatalytic material and a second branch includes a second electrocatalytic material.

FIG. 7 illustrates an embodiment of an electrode system hereof wherein a first electrode and a second electrode are supported upon a gas porous disk, which is formed as an annulus.

FIG. 8 illustrates the response of a representative example of a single channel amperometric sensor hereof having a single electrode fabricated to include an electrocatalytic material that is responsive to an analyte, to exhaled breath and to nitrogen

FIG. 9 illustrates a decision tree diagram setting forth a representative embodiment of an operating mode or method of a system hereof.

FIG. 10 illustrates an equivalent circuit used to describe electrochemical cells.

FIG. 11 illustrates a block diagram of an embodiment of measurement circuitry for electronic interrogation.

DETAILED DESCRIPTION OF THE INVENTION

As used herein and in the appended claims, the singular forms “a,” “an”, and “the” include plural references unless the context clearly dictates otherwise. Thus, for example, reference to “a transport path” includes a plurality of such transport paths and equivalents thereof known to those skilled in the art, and so forth, and reference to “the transport path” is a reference to one or more such transport paths and equivalents thereof known to those skilled in the art, and so forth.

As, for example, illustrated schematically in FIG. 1, in a number of embodiments, the devices, systems and/or methods hereof are operable to test transport properties of a gas detection or other system 10 via application of a driving force other than an analyte gas or a simulant gas (that is, a gas simulating the analyte gas by evoking a response from the analytical electrode of the system) from a container to one or more inlets 22 of an enclosing housing 20 of system 10. In a number of embodiments, the driving force may, for example, be the application of exhaled breath to inlet(s) 22. Housing 20 may, for example, include a mass transport path into an interior thereof (for example, a diffusion path) in fluid connection with inlet 22. The path may, for example, include or be in fluid connection with a mass transport or diffusion member or barrier 30 (for example, a membrane through which gas is mobile (for example, via diffusion) but through which a liquid has limited or no mobility). Housing 20 encloses a sensor 40 which is sensitive to the presence of exhaled breath. For example, sensor 40 may be sensitive to an environmental gas (the concentration of which is changed by the presence of exhaled breath), to a gas within exhaled breath, to a change in humidity, to a change in temperature, to a change in pressure, to a change in flow etc. A response of sensor 40 to exhaled breath provides a measurement of the transport properties and/or functionality of one or more transport paths of system 10.

In a number of representative embodiments discussed herein, devices, systems and/or methods hereof decrease or eliminate the necessity to bump check a gas detection instrument with stored calibration (for example, an analyte or a simulant) gas. Such representative embodiments of systems, devices and/or methods may, for example, combine an internal, electronic check or interrogation of sensor functionality, connection, and/or correction (as, for example, described in U.S. Pat. No. 7,413,645) with a transport path test using a “secondary” sensor sensitive to a driving force other than the presence of an analyte gas or a simulant gas (for example, a driving force/variable change arising from the presence of exhaled human breath as described above).

Many gas detection devices, instruments or systems (for example, portable gas detection instruments) include amperometric electrochemical gas sensors. These sensors are often referred to as “fuel cell” type sensors, which refers to a primary principle of operation. Such electrochemical gas sensors are typically combined or integrated into a device, system or instrument with a battery or other power supply, appropriate electronic driving circuitry (for example, including a potentiostat), a display, and one or more alarms (or other means of communicating to the user the presence of a dangerous level of harmful or toxic gas or a condition of dangerous oxygen depletion or enrichment). The sensor, circuitry and displays are typically contained in a rugged, sealed housing. As used in connection with such an instrument, the term “sealed” refers to protection of the sensor, circuitry, and displays from harmful environmental hazards (for example, dusts, condensing vapors, such as paints or coatings, and water and/or other liquids). However, the sealed housing must continually provide for the efficient transfer of the target or analyte gas(es) from outside the instrument housing into a housing of the sensor itself. Often, this result is accomplished with one or more porous diffusion membranes that keep dusts, vapors, and liquids out of the instrument housing, but allow one or more analyte gases of interest to be transported into the sensor itself. This transport is typically accomplished by gaseous diffusion or by pumping an analyte gas stream into or across the face of the sensor.

As described above, the need to bump check a gas detection system/device with a calibration or simulant gas from a container is decreased or eliminated by providing a sensor (for example, a secondary sensor) that is sensitive to or responds to a driving force or variable change in the vicinity of the inlet of the system, such as, for example, the presence of exhaled breath. In a number of embodiments, components which make a sensor responsive to oxygen are provided in an amperometric electrochemical sensor (which is functional to detect an analyte other than oxygen). Exhaled human breath typically includes 4 to 5 volume-percent (vol-%) of carbon dioxide (CO₂) and 15.8 to 16.8 vol-% oxygen (O₂). In contrast, ambient air includes approximately 20.8 vol-% O₂ and 0.035 vol-% CO₂. Thus, when a user exhales in the vicinity of one or more inlets into the housing of the detection system or instrument, the exhaled breath displaces the volume of gas (ambient air) within a diffusion volume in a sensor therein with the exhaled breath. A response to the decreased concentration of oxygen in exhaled breath as compared to ambient air may be used to test the transport properties of whatever gas transport path or mechanism may be used in the gas detection device (for example, including one or more gas diffusion membranes). The same result may, for example, be accomplished by incorporating, within or along with, for example, a toxic gas, a combustible or other sensor channel, a sensing element (which may be the same as or different from the sensing element for the analyte) that responds to any or all components of exhaled breath. For example, a similar result may be obtained by including a sensor or sensing functionality that responds to the increased concentration of CO₂ in exhaled breath as compared to ambient air. In that regard, exhaled breath contains approximately 5 vol % CO₂, as compared to ambient air, which contains approximately 600 ppm CO₂ (0.06 vol-%). A sensor or sensing system to measure CO₂ concentration may, for example, include an electrochemical sensor and/or a non-dispersive infrared sensor.

Amperometric or fuel cell-type gas sensors typically include at least two electrocatalytic electrodes (an anode and a cathode), at least one of which is a gas diffusion electrode or working electrode. The working electrode can be either the anode or the cathode in any given sensor. The gas diffusion electrode typically includes fine particles of an electrocatalytic material adhered to one side of a porous or gas-permeable membrane.

The electrocatalytic side of the working electrode is in ionic contact with the second electrode (the counter electrode, whether the anode or the cathode) via an electrolyte (for example, a liquid electrolyte, a solid electrolyte, a quasi-solid state electrolyte or an ionic liquid). A liquid electrolyte is typically a solution of a strong electrolyte salt dissolved in a suitable solvent, such as water. An organic solvent may also be used. Quasi-solid state electrolytes can, for example, include a liquid electrolyte immobilized by a high-surface-area, high-pore-volume solid. The working electrode and the counter electrode are also in electrical contact via an external circuit used to measure the current that flows through the sensor.

Additionally, although by no means necessary, a third or reference electrode, is often included. The reference electrode is constructed in a way that its potential is relatively invariant over commonly occurring environmental conditions. The reference electrode serves as a fixed point in potential space against which the operating potential of the working electrode may be fixed. In this way, electrochemical reactions that would not normally be accessible may be used to detect the analyte gas of interest. This result may be accomplished via control and driving circuitry which may, for example, include a potentiostat.

FIGS. 2A through 2C illustrate a schematic diagram of an instrument or system 100 including at least one electrochemical sensor or sensor system 110. System 100 includes a system housing 102 including an inlet or inlet system 104 which places an interior of system housing 102 in fluid connection with the ambient environment. Electrochemical sensor system 110 includes at least one primary sensor responsive to at least one analyte gas. System 100 further includes at least one secondary sensor which is responsive to a driving force or variable change outside of system housing 102 in the vicinity of inlet 104 other than a change in concentration of the analyte gas or a simulant gas (that is, a gas other than the analyte gas to which the primary sensor is responsive) applied to system 100 from a container. A system 50 for creating such a driving force or variable change is illustrated schematically in FIG. 2A. System 50 may, for example, change the concentration of a gas, change humidity, change temperature, change pressure, change flow etc. in the vicinity of system inlet 104. The secondary sensor is responsive to the driving force created by system 50. The response of the secondary sensor to the driving force is indicative of the state of the path or transport path between inlet 104 and the secondary sensor. In general, the transport path is the path via which a gas is transported from outside housing 102 (via inlet 104) to the secondary sensor (whether by, for example, diffusion or pumping). The transport path between inlet 104 and the secondary sensor and the transport path between inlet 104 and the primary sensor may, for example, be the same or similar and are exposed to generally the same conditions over the life of system 100. The secondary sensor may, for example, be positioned in close proximity to the primary sensor. The response of the secondary sensor to the driving forces provides an indication of the state of the transport between system inlet 104 and the primary sensor.

In a number of representative embodiments described herein, system 50 represents a person who exhales in the vicinity of inlet 104. In the case of exhaled breath, the driving force may be any one of (or more than one of) a change in the concentration of a gas (for example, oxygen or carbon dioxide), a change in humidity, a change in temperature, a change in pressure, or a change in flow. The secondary sensor may thus include a gas sensor, a humidity sensor, a temperature sensor, a pressure sensor and/or a flow sensor. In the case that, for example, the secondary sensor is a humidity sensor, a temperature sensor, a pressure sensor or a flow sensor, system 50 need not be a person who exhales in the vicinity of system inlet 104. System 50 may, for example, be any system or device suitable to create a change in humidity, a change in temperature, a change in pressure, or a change in flow. The degree of change in the variable of interest may, for example, be controlled to monitor for a corresponding response of the secondary sensor. In the case of a change in temperature, system 50 may, for example, including a heating element. In the case of a change in pressure or a change in flow, system 50 may, for example, include a small, manually operated air pump such as a bellows.

In a number of representative embodiments hereof, the secondary sensor includes a gas sensor responsive to the concentration of a gas which is changed by exhalation in the vicinity of system inlet 104. In several such embodiments, sensor 110 includes a housing 120 having a gas inlet 130 (formed in a lid 122 of sensor housing 120) for entry of analyte gas and human breath into sensor 110. In the illustrated embodiment, inlet 130 is in fluid connection with a gas diffusion volume or space 118. Electrolyte saturated wick materials 140 a, 140 b and 140 c separate a first working electrode 150 a (responsive to the presence of analyte gas) and a second working electrode 150 b (responsive to the presence of human breath) from reference electrode(s) 170 and counter electrode(s) 180 within sensor 110 and provide ionic conduction therebetween via the electrolyte absorbed therein. First working electrode 150 a, reference electrode 170 and counter electrode 180, in cooperation with electrolyte saturated wick materials 140 a, 140 b and 140 c form a portion of the primary sensor. Second working electrode 150 b, reference electrode 170 and counter electrode 180, in cooperation with electrolyte saturated wick materials 140 a, 140 b and 140 c form a portion of the secondary sensor. Electronic circuitry 190 as known in the art is provided, for example, to maintain a desired potential between working electrodes 150 a and 150 b and reference electrode(s) 170, to process an output signal from sensor 110 and to connect/communicate with other components of system 100 (including, for example, one or more displays, communication systems, power supplies etc.).

In the illustrated embodiment, first working electrode 150 a and second working electrode 150 b are located to be generally coplanar within sensor housing 120. In the illustrated embodiment, first working electrode 150 a is formed by depositing a first layer of catalyst 154 a on a diffusion membrane 152 (using, for example, catalyst deposition technique known in the sensor arts). Second working electrode 150 b is also formed by depositing a second layer of catalyst 154 b on diffusion membrane 152 (using, for example, catalyst deposition techniques known in the sensor arts). Methods of fabricating electrodes on diffusion membranes are, for example, described in U.S. Patent Application Publication No. 2011/0100813. Catalyst layers 152 a and 152 b may or may not be formed using the same electrocatalytic material. It is immaterial whether second gas diffusion or working electrode 150 b is operated as an anode or cathode with respect to the operation of first gas diffusion or working electrode 150 a.

FIGS. 3A through 3D illustrate an embodiment of a sensor 210 that is similar in design and operation to sensor 110. Like elements of sensor 210 are numbered similarly to corresponding elements of sensor 110 with the addition of 100 to the reference numbers of the elements of sensor 210. As illustrated in FIG. 3A, reference electrode 270, counter electrode 280 and electrolyte absorbent wicks 240 a, 240 b and 240 c are supported within housing 220 via a support member 284. A printed circuit board 292 is connected to housing 220 and may form a part of the electronic circuitry of sensor 210.

As, for example, illustrated in FIGS. 3A and 3C, a housing lid 222 includes a first gas inlet 230 a and a second gas inlet 230 b. First gas inlet 230 a and a second gas inlet 230 b may, for example, be in fluid connection with an inlet system 204 (including, for example, one or more inlets) formed in a housing 202 of an instrument or system 200 (see FIG. 3B). First inlet 230 a can, for example, be designed for use in connection with a first working electrode 250 a for an analyte gas such as hydrogen sulfide. A first catalyst layer 254 a of first working electrode 254 a, which is deposited upon a first diffusion membrane 252 a, may, for example, include iridium in the case that the analyte gas is hydrogen sulfide (H₂S). Second inlet 230 b is designed for use in connection with the application of exhaled breath to second working electrode 250 b. Second working electrode 250 b is formed by deposition of a second catalyst layer 254 b upon a second diffusion membrane 252 b. Separate gas inlets 230 a and 230 b may, for example, be designed or optimized for passage of two different gases. In that regard, first gas inlet 230 a may be optimized (for example, in dimension and/or shape) for the analyte gas of interest, while second gas inlet 230 b may be optimized for a component of exhaled breath.

In the case of an aqueous electrolyte, the material(s) (which can be the same or different) of the gas diffusion membranes can be generally hydrophobic in nature to minimize or eliminate any flow of the aqueous electrolyte therethrough. In the case of a non-aqueous (for example, organic) electrolyte, the material of the gas diffusion membranes can be generally oleophobic in nature to minimize or eliminate any flow of the non-aqueous electrolyte therethrough. The material(s) can also be hydrophobic and oleophobic. Such materials are referred to as “multiphobic”. The materials can also be chemically or otherwise treated to minimize or eliminate liquid electrolyte flow or leakage therethrough.

In general, the term “hydrophobic” as used herein refers to materials that are substantially or completely resistant to wetting by water at pressures experienced within electrochemical sensors (and thus limit flow of aqueous electrolyte therethrough). In general, the term “oleophobic” as used herein refers to materials that are substantially or completely resistant to wetting by low-surface tension liquids such as non-aqueous electrolyte systems at pressures experienced within electrochemical sensors (and thus limit flow of non-aqueous electrolyte therethrough). As used herein, the phrase “low-surface tension liquids” refers generally to liquids having a surface tension less than that of water. Hydrophobic, oleophobic, and multiphobic materials for use in electrodes are, for example, discussed in U.S. Pat. No. 5,944,969.

Gas diffusion membranes for use herein can, for example, be formed from polymeric materials such as, but not limited to, polytetrafluoroethylene (for example, GORETEX®), polyethylene or polyvinylidene fluoride (PVDF). Such polymeric materials can, for example, include a pore structure therein that provides for gas diffusion therethrough.

In sensors 110 and 210, first working electrodes 150 a and 250 a share a common electrolyte, a common counter electrode (180 and 280) and a common reference electrode (170 and 270) with second working electrodes 150 b and 250 b, respectively. In certain situations, depending, for example, upon the analyte gas to be detected and the associated electrochemistry, it may not be desirable or possible to have a common electrolyte, counter electrode and/or reference electrode. FIG. 3E illustrates another embodiment of a sensor 210′, which is similar in operation and construction to sensors 110 and 210. Unlike sensors 110 and 210, in the embodiment of 210′, first working electrode 250 a′ and second working electrode 250 b′ are positioned in separate cells within housing 120″ which are not in fluid connection. In this manner, a different electrolyte can be used in connection with electrolyte saturated wick materials 140 a′, 140 b′ and 140 c′ than the electrolyte used in connection with electrolyte saturated wick materials 140 a″, 140 b″ and 140 c″. Likewise, reference electrode 170 a′ may be formed differently from reference electrode 170 b′, and/or counter electrode 180 a′ may be formed differently from counter electrode 180 b′. In the illustrated embodiment, separate inlets 230 a′ and 230 b′ are formed in a common lid or cap 222′ to be in fluid connection with first working electrode 250 a′ and second working electrode 250 b′, respectively.

FIGS. 3F and 3G illustrates another embodiment of a sensor 310, which is similar in operation and construction to sensors 110 and 210. Sensor 310 includes a housing 320 having a gas inlet 330 (formed in a lid 322 of sensor housing 320) for entry of analyte gas and human breath into sensor 110. In the illustrated embodiment, inlet 330 is formed as an extending slot in lid 322 and is in fluid connection with a gas diffusion member 318. Gas diffusion member 318 is, for example, formed from a porous polymeric material and provides for relatively quick lateral diffusion of gas to a first working electrode 350 a (responsive to the presence of analyte gas) and a second working electrode 350 b (responsive to the presence of human breath) to reduce response times of sensor 310. First working electrode 350 a, second working electrode 350 b, and remainder of the components of sensor 330, may, for example, be formed in the same manner as described above for working electrode 150 a, second working electrode 150 b and the remainder of the components of sensor 110. Gas diffusion member 318 may, for example, be stiffer in construction than diffusion membrane 352 a of first working electrode 350 a and diffusion membrane 352 b of second working electrode 350 b (upon which, catalyst layers 354 a and 354 b, respectively, are deposited). In addition to providing relatively quick lateral diffusion, gas diffusion member 318 may also protect diffusion membranes 352 a and 352 b from “pinching” as a result of mechanical compression.

Although the transport paths for first working electrodes 250 a, 250 a′ and 350 a and for second working electrodes 250 b, 250 b′ and 350 b of sensor 210, 210′ and 310 are slightly different, all transport paths in a particular instrument experience generally the same environments and environmental conditions. Therefore, a challenge with exhaled breath and the measured response of second working electrodes 250 b, 250 b′ and 350 b thereto provides an indication of the functionality of all transport paths in the system or instrument.

In several studies of sensors fabricated in the manner of sensor 210 hereof, first gas diffusion or working electrode 250 a was used to detect hydrogen sulfide (H₂S), while second gas diffusion or working electrode 250 b was used to detect the oxygen component of exhaled breath. Sensors fabricated in the manner of sensor 110, sensor 210′ or sensor 310 would operate in the same manner. In the specifically studied embodiments, first electrocatalyst layer 254 a included iridium (Ir) metal. Second electrocatalyst layer 254 b included platinum (Pt) metal, Other electrocatalysts suitable for reduction of oxygen may be used in second electrocatalyst layer 254 b.

FIG. 4 illustrates the behavior sensor 210 when challenged with exhaled breath, followed by a mixture of 15 vol-% oxygen and 20 ppm hydrogen sulfide, followed by nitrogen. The H₂S channel trace is the response of first working electrode 250 a (designed to detect hydrogen sulfide), and the O₂ channel trace is the response of second working electrode 250 b (designed to detect the oxygen component of exhaled breath). As illustrated, second working electrode 250 b responds to the decreased oxygen content of exhaled breath which occurs at approximately the 50 second mark in the graph. A mixture of 15 vol-% oxygen and 20 ppm hydrogen sulfide was applied at approximately 100 seconds. Each of first working electrode 250 a and second working electrode 250 b responded appropriately to this challenge gas. Finally, nitrogen was applied at 250 seconds. Upon application of nitrogen, second working electrode 250 b (designed for the detection of oxygen) responded appropriately to the challenge gas.

The response of second working electrode 250 b to exhaled breath as shown in FIG. 4 may, for example, be used to determine that the transport paths (including gas diffusion members and/or membranes) of a portable gas detection instrument are, for example, not compromised by dust, vapors, and/or liquid. That is, based on the response of second working electrode 250 b to the decreased oxygen concentration of exhaled breath, it can be determined that there is appropriate flow through all gas diffusion members (for example, gas diffusion membranes 252 a and 252 b), whether they are part of sensor 210 itself or part of the overall instrument. This gas response, when combined with an internal electronic interrogation signal such as that described in U.S. Pat. No. 7,413,645, may be used to provide a check of both the internal conductive condition of an amperometric electrochemical sensor and any gas transport path(s) (including, for example, associated gas diffusion membranes), whether part of the sensor cell itself or part of the overall instrument. In this manner, a test similar in overall result to a bump test is accomplished without the use of expensive and potentially hazardous calibration gas and equipment associated therewith.

In a number of embodiments hereof for use in connection with an exhaled breath test or bump check, an amperometric oxygen (or other gas) sensing element is disposed within, for example, an amperometric toxic (or other) gas sensor for detecting an analyte of interest. In a number of the embodiments described above, both an analyte gas sensing working electrode and the oxygen sensing electrode are conventionally fabricated as gas diffusion electrodes. In many cases, such gas diffusion electrodes include a high surface area electrocatalyst dispersed on a porous support membrane. In embodiments in which an amperometric gas sensor is used in systems hereof as a secondary sensor to test one or more transport paths, because the secondary sensor (for example, an oxygen sensor) is not used to present an analytical signal, there may be no need to use either a gas diffusion electrode or a high surface area electrocatalyst.

For example, a conductor such as a contact ribbon or another conductive member, which are often used to carry an electrical signal from a gas diffusion electrode, may have sufficient surface area and electrocatalytic activity to be used as an oxygen, CO₂ or other gas sensitive electrode. For example, FIG. 5A illustrates a ribbon 450 a and a wire 450 a′ which may be used to form a non-analytical sensor element in the systems hereof. Such ribbons or wires may, for example, be fabricated from an electrocatalytic material such as Platinum (Pt), Iridium (Ir), Gold (Au) or carbon (C). As illustrated in FIG. 5B sensor elements 550 a and 550 a′ hereof may, for example, be a conductive ribbon 552 a or a conductive wire 552 a′, respectively, upon which an electrocatalytic material 554 a and 554 a′ (for example, Pt, Ir, Au, C etc.), respectively, is coated or immobilized. The material of ribbon 552 a and wire 552 a′ may be the same or different from electrocatalytic material 554 a and 554 a′ immobilized thereon.

The sensor elements or electrodes hereof for testing transport paths may take a wide variety of two-dimensional or three-dimensional shapes. For example, FIG. 5C illustrates a sensor element 650 a hereof including an extending ribbon 652 a having a rectangular end member 653 a which is wider than extending ribbon 652 a to, for example, provide increased surface area per unit length as compared to a ribbon of the same length. Similarly, FIG. 5D illustrates a sensor element 650 a′ hereof including an extending ribbon 652 a′ having a rectangular end member 653 a. In the embodiment of FIG. 5D, an electrocatalytic material 654 a′ is immobilized on end member 653 a. FIG. 5E illustrates a sensor element 750 a hereof including an extending wire 752 a having a spiraled section 653 a on an end thereof, which may, for example, provide increased surface area per unit length as compared to an extending wire of the same length. Similarly, FIG. 5F illustrates a sensor element 750 a′ hereof including an extending wire 752 a′ having a spiraled section 653 a on an end thereof. In the embodiment of FIG. 5F, an electrocatalytic material 754 a′ is immobilized on spiraled section 753 a′. In the embodiments of FIGS. 5D and 5F, electrocatalytic materials 654 a′ and 754 a′ may be the same or different as the material upon which the electrocatalytic material is immobilized.

In the embodiments discussed above, a first electrode is used for sensing an analyte and a second electrode, formed separately from the first electrode, is used to, for example, detect oxygen concentration. In the representative example of a toxic gas sensor for detecting the analyte H₂S, for example, the toxic gas channel (H₂S, in that case) is fabricated to include the electrocatalyst iridium (Ir) and the oxygen-sensing electrode is fabricated to include the electrocatalyst platinum (Pt). Those electrocatalysts may, for example, be independently dispersed onto the same porous substrate, but in two distinct and different areas. The same or similar functionality may, for example, be achieved if mixtures of Pt and Ir are used. For example, such mixtures may be physical mixtures of high surface area catalytic powders or such mixtures may be alloys. In a number of embodiments, one electrocatalytic substance or material may, for example, be fabricated on top of another electrocatalytic substance or material in a two-step process.

Moreover, the two electrocatalytic materials may, for example, be fabricated into an interdigitated electrode system. FIG. 6 illustrates an embodiment of an interdigitated electrode system 850 wherein a first branch 850 a of electrode system 850 includes a first electrocatalytic material and a second branch 850 b includes a second electrocatalytic. The first and second electrocatalytic materials of the two branches or “fingers” 850 a and 850 b of electrode system 850 may, for example, be fabricated to include the same electrocatalytic substance (or mixture of substances) or to include different electrocatalytic substances.

In another embodiment of an electrode system 950 hereof illustrated in FIG. 7, a first electrode 950 a and a second electrode 950 b are supported upon a gas porous disk 960, which is formed as an annulus in the illustrated embodiment. Disk 960 may, for example, be fabricated from gas porous or permeable (that is, adapted to transport gas therethrough) polymer or another material that is inert in the electrolyte used in the sensor system. As described above, disk 960 serves as an electrode support onto which first working electrode 950 a and secondary working electrodes 950 b are fabricated, but on opposite sides of disk 960 as illustrated in FIG. 7. First or upper electrode 950 a (in the orientation of FIG. 7) is formed as an annulus. Second or bottom electrode 950 b is formed as a disk centered on the annulus of disk 960. Electrode system 950 further includes a first or upper electrolyte wick 970 a and a second or lower electrolyte wick 970 b. Electrode system also includes a first electrode current collector 980 a and a second electrode current collector 980 b.

The configuration of FIG. 7 may, for example, be vertically flipped or rotated 180° from its illustrated orientation and still function as intended. Many other shapes and configuration of electrodes are possible for use herein. Moreover, electrodes hereof may, for example, be stacked in multiple layers or other arrangements to produce sensors with a sensitivity for a multiplicity of target gases.

In a number of embodiments hereof, a single working or sensing electrode can be used which responds to both the analytical gas of interest (analyte) and to a another driving force (for example, a component of exhaled breath) to enable testing of one or more transport paths to the electrode(s) of the system. For example, in the representative sensor system described in FIG. 2, the H₂S working electrode also responds to exhaled breath. The response of the working electrode to exhaled breath can be used to test the function of the transport path. FIG. 8 illustrates the response of a representative example of a single channel amperometric sensor having a single electrode fabricated to include an electrocatalytic material that is responsive to an analytical gas of interest or analyte (H₂S in the representative example), to exhaled breath and to nitrogen. The electrode may be fabricated from a single electrocatalytic material, a physical mixture of electrocatalytic materials or an alloy of electrocatalytic materials.

In a number of embodiments of sensor systems hereof, two sensing or working electrodes are provided which include the same electrocatalytic material immobilized thereon. The electrodes can, for example, be fabricated in an identical manner. In such embodiments, the analyte gas and, for example, a gas of interest in exhaled breath are each electroactive on the electrocatalytic material. In a number of embodiments, the function of the two electrodes is alternated (for example, each time the user activates a breath check as described above). Referring to, for example, FIG. 6, the first and second electrocatalytic materials of the two branches or electrodes 850 a and 850 b of electrode system 850 would include the same electrocatalytic material. In a first instance of activation of the instrument including electrodes 850 a and 850 b, electrode 850 a would be used as the working electrode for the target analyte gas and electrode 850 b would be used to, for example, detect a component of exhaled breath (for example, oxygen). The next time the user activates the internal breath check (a second instance), the functions of electrodes 850 a and 850 b would be switched by the external circuitry and logic of the system or instrument including sensors 850 a and 850 b. That is, in the second instance, electrode 850 b would be used as the working electrode for the target analyte gas and electrode 850 a would be used to detect the component of exhaled breath. In this manner, alternatively, each electrode area would be calibrated against the target gas of interest and the electronic life and health checks described below would be periodically applied to each electrode. Such a system and methodology provides a greater amount of surveillance and surety to the test methodology. A detection or sensing element switching scheme which may be adapted for user herein is described in U.S. Patent Application Publication No. 2011/0100090, the disclosure of which is incorporated herein by reference.

In the case that oxygen variation (for example, as a result of a breath test) is measured, sensing elements other than amperometric oxygen sensing element may, for example, be used. In that regard, any alternative oxygen sensing system may be used in place of an amperometric oxygen sensing. Representative examples of suitable oxygen sensing systems include, but are not limited to, a metal oxide semiconductor or MOS (also colloquially referred to as a “Figaro” sensor) oxygen sensing element, a high temperature potentiometric oxygen sensor (zirconia sensor), or a paramagnetic oxygen sensor. A particular oxygen sensing technology may, for example, be more suitable as a complement to a given toxic gas or other sensing technology for a particular use. For example, an MOS or zirconia-based oxygen sensing element may be well suited for use with an MOS toxic sensor or with a heated catalytic bead combustible gas sensor.

FIG. 9 illustrates a decision tree diagram that depicts a representative embodiment of an operating mode or method hereof. The method illustrated in FIG. 9 assumes a successful complete calibration of the instrument (with a calibration gas) at some point in time, either at final assembly and testing or in the field. In daily use, when the instrument is turned on, as is typical, the instrument will perform its necessary self-diagnosis checks. Part of this self-diagnosis may, for example, include the application of a life and health check similar to that described in U.S. Pat. No. 7,413,645.

As described in U.S. Pat. No. 7,413,645, and as illustrated in FIG. 10, a sensor generally can be described as a combination of resistances and capacitance in series. The resistance R_(R) resulting from the reference electrode of FIG. 10 is not part of the current path of the analytical signal of the sensor. The resistive portion of this circuit is primarily a result of the solution (ionic) resistance of the electrolyte interspersed between the working electrode (R_(W)) and the counter electrode (R_(C)). The capacitive portion (C_(W)) of the equivalent circuit is primarily a result of the micro solution environment found very close to the surfaces of the metallic particles that comprise the working electrode. As a result of electrostatic forces, the volume of solution very close to the electrode surface is a very highly ordered structure. This structure is important to understanding electrode processes. The volume of solution very close to the electrode surface is variously referred to as the diffusion layer, diffuse layer, and or the Helmholtz layer or plane.

The magnitudes of the resistance and capacitance present in an electrochemical cell are a result of the nature and identities of the materials used in its fabrication. The resistance of the electrolyte is a result of the number and types of ions dissolved in the solvent. The capacitance of the electrode is primarily a function of the effective surface area of the electrocatalyst. In an ideal world, these quantities are invariant. However, the solution resistance present in an amperometric gas sensor that utilizes an aqueous (water-based) electrolyte may change, for example, as a result of exposure to different ambient relative humidity levels. As water transpires from the sensor, the chemical concentration of the ionic electrolyte increases. This concentration change can lead to increases or decreases in the resistivity of the electrolyte, depending on the actual electrolyte used.

The response curves of sensors have the shape expected for the charging curve of a capacitor, that is a typical “RC” curve. In a number of embodiments, the analytical signal used to determine the “health” of a sensor is the algebraic difference in the observed potential just prior to the application of a current pulse and at the end of the current pulse. The magnitude of the potential difference observed as a function of the application of the current pulse is an indicator of the presence and the health of the sensor.

Although limitations on the magnitude and duration of the current pulse have mostly to do with experimental convenience, the magnitude of the current pulse may, for example, be chosen to correspond to application of a reasonably expected amount of target gas.

Sensor presence and health may be determined by the shape of the sensor's RC charging curve, being measured by observing the difference in sensor output at the beginning and the end of the current pulse. If the sensor is absent, the observed potential is equal to that which would be expected based on the magnitudes of the current pulse and the sensor load resistor.

FIG. 11 illustrates a block diagram of one embodiment of an electronic interrogation circuit as described in U.S. Pat. No. 7,413,645 and as used in several embodiments of the systems described herein. In FIG. 11, the voltage follower and the current follower sections function as known to one skilled in the art. See, for example, A. J. Bard and L. R. Faulkner, Electrochemical Methods: Fundamentals and Applications, John Wiley & Sons: New York (1980), the disclosure of which is incorporated herein by reference. The voltage follower maintains a constant potential between the reference electrode (R) and the working electrode (W). The current follower buffers and amplifies currents which flow in the electrochemical sensor between the counter electrode (C) and the working electrode (W). In an number of embodiments, the current pump applies electronic interrogation to the sensor by forcing a known current to flow between the counter electrode (C) and the working electrode (W).

Following an electronic interrogation test as described above, the user may, for example, be prompted to perform an exhaled breath test or a “bump check” hereof (without calibration gas) by exhaling closely into the instrument face. Embedded instrument software observes the resulting signal on, for example, second working electrode 250 b (designed to respond to some driving force/variable change associated with exhaled breath such as a change in oxygen concentration). In the embodiment of sensor 210, the observed response is decreased oxygen content in exhaled human breath. The embedded instrument control software compares the result of the electronic interrogation test and the result of the exhaled breath test to established parameters. If the responses of either the electronic interrogation test or the exhaled breath test fail to meet these pre-established criteria, the instrument may prompt the user to perform a full calibration or some other maintenance. If the results of both the electronic interrogation test and the exhaled breath test meet or exceed the pre-established criteria, the instrument may indicate to the user that it is functioning properly and is ready for daily use.

The foregoing description and accompanying drawings set forth the preferred embodiments of the invention at the present time. Various modifications, additions and alternative designs will, of course, become apparent to those skilled in the art in light of the foregoing teachings without departing from the scope of the invention. The scope of the invention is indicated by the following claims rather than by the foregoing description. All changes and variations that fall within the meaning and range of equivalency of the claims are to be embraced within their scope. 

What is claimed is:
 1. A method of testing a system having at least one electrochemical sensor for detecting an analyte gas within a housing of the system, the housing of the system having an inlet, comprising: exhaling in the vicinity of the inlet of the housing of the system; and measuring a response to exhaled breath to test one or more transport paths of the system.
 2. The method of claim 1 wherein measuring the response to exhaled breath comprises measuring the response of a sensor within the housing of the system that is responsive to the presence of exhaled breath.
 3. The method of claim 2 wherein the sensor responsive to the presence of exhaled breath comprises an electrochemically active electrode responsive to a gas within exhaled breath.
 4. The method of claim 3 wherein the electrochemically active electrode is responsive to carbon dioxide.
 5. The method of claim 3 wherein the electrochemically active electrode is responsive to oxygen.
 6. The method of claim 3 further comprising: simulating the presence of the analyte gas electronically; and measuring a response of the electrochemical sensor to the electronic simulation.
 7. The method of claim 6 wherein a constant current is caused to flow between a first working electrode and a counter electrode of the electrochemical sensor and the measured response is a potential difference.
 8. The method of claim 6 wherein a constant potential difference is maintained between a first working electrode and a counter electrode of the electrochemical sensor and the measured response is a current.
 9. The method of claim 6 wherein the electrochemical sensor is an amperometric sensor.
 10. The method of claim 6 wherein the electrochemical sensor comprises a first working electrode responsive to the analyte gas and a second working electrode responsive to a gas within exhaled breath.
 11. The method of claim 10 wherein the electrochemical sensor comprises a sensor housing comprising at least one inlet into an interior of the sensor housing, the first working electrode and the second working electrode being positioned within the sensor housing.
 12. The method of claim 11 wherein each of the first working electrode and the second working electrode independently comprises an eletrocatalytically active material deposited upon a porous membrane through which gas can diffuse.
 13. The method of claim 3 wherein the electrochemically active electrode comprises a wire or a ribbon.
 14. The method of claim 13 wherein the wire or the ribbon comprises an eletrocatalytically active material deposited thereon.
 15. The method of claim 13 wherein the electrochemically active electrode comprises a section of increased surface area per unit length in operative connection with the wire or the ribbon.
 16. The method of claim 2 wherein the sensor responsive to the presence of exhaled breath is the same as the at least one electrochemical sensor, which comprises a first electrochemically active electrode responsive to a gas within exhaled breath and responsive to the analyte gas.
 17. The method of claim 26 wherein the system further comprises a second electrochemically active electrode responsive to a gas within exhaled breath and responsive to the analyte gas.
 18. The method of claim 17 further comprising alternating the function of the first electrically active electrode and the second electrically active electrode between sensing the gas within exhaled breath and sensing the analyte gas.
 19. A system, comprising: a system housing, at least one inlet formed in the system housing, at least one electrochemical sensor for detecting an analyte gas within the system housing and at least one sensor responsive to the presence of exhaled breath within the system housing.
 20. A system for detecting at least one analyte gas, comprising: a system housing comprising an inlet system; an electrochemical gas sensor within the housing and in fluid connection with the inlet system, the electrochemical sensor being responsive to the at least one analyte gas, and at least one other sensor within the housing and in fluid connection with the inlet system, the at least one other sensor being responsive to at least one driving force created in the vicinity of the inlet system other than by application of the at least one analyte gas or a simulant gas to which the electrochemical sensor is responsive to provide an indication of a state of a transport path between the inlet system and the electrochemical gas sensor. 